TVJMPPL/SM/PV1/ JAN2019/5

STRATEGY FOR CAPACITY ENHANCEMENT OF MILLING CIRCUITS OF PELLETIZATION PLANTS AT

SAMPALPUR,ORISSA ANDJAMORIA, WEST BENGAL OF M/S SHAYM METALLICS, KOLKATA, INDIA
EXECUTIVE SUMMARY
M/s Shyam Metallics, Kolkatta who is expanding the capacity of pellet plants requested TVJMPP Bangalore
to study possibility of increasing milling circuits capacity matching the enhanced capacity of pellet plant on a
promotional basis. It was found that by feeding -5 mm fraction of feed, coarsening the pellet feed size to - 0.3mm,
50-60% minus 0.045mm, removal of finished 0.3mm by adjusting the spiral classifier, employment of additional
hydro- cyclones, maintaining pulp consistency as short term modification and implementing the high frequency 0.3
mm screens for cyclone under flow as medium term modification before secondary ball mill – cyclone circuit, can just
match 1.8 MTPY pellet production by producing 360 tph cake and medium term modification yields 420 tph cake
production matching the requirements.,respectively. As a long term measure, a 0.3 mm screen - 12’ x20’ ball mill
with 2250KW drive can give have maximum capacity of nearly 350 tph keeping the 33% -0.3mm in- 5 mm feed, 10%
extra capacity due to high diameter factor and 25% extra capacity due to reduction of circulating load and efficient
screening, catering future pellet lane expansion. While conducting the short term modification, the equipment
manufacturers may also be consulted and the values are based on granulometry,WI of feed and products. It was
reported that the dewatering units have sufficient capacity to meet the 2MTPY pellet production.
1 INTRODUCTION
M/s Shaym metallics [SM] Iis a renown group in India producing diverse value added steel products, ferro
alloys, cement and energy based on theme ore to metal. making judicious use of raw materials like iron ore fines,
coal, chromite, manganese ores and clinkers in an integrated in Jamuria, West Bengal which are forward and
backward integrated.. The SMi s consistently growing in financial and operational metrics.
The units at Sambalpur and Jamuria each had an identical grate kiln pelletizing units of design value of
0.6MTPA high grade pellets. at 100 tph[ for minimum 6000 hrs /year; 20hrs/day x 25 days/ month x 12 months/year]
The milling and filtration circuit in twin lane was designed for 120 tph for both circuits [60 tph/circuit lane] . It
comprised of grinding -25mm high grade iron ore in a primary grate ball mill [2.7 x 3.6 m, 400 KW ] in closed circuit
with spiral classifier [Duplex Classifier with 2 screws of 1.85 m dia x 11.5 m long triple pitch, 3 starts with adjustable
overflow weirs and full flared tank of 4.8 m width and max depth of 2.78 m with a maximum capacity of 600 tph]
yielding -0.2mm in over flow. The over flow is ground to -0.07mm D 80 0.045 mm in cyclone ball mill circuit using 8 Nos
250 mm dia hydrocyclones and a secondary overflow ball mill [2.7 x 3.6 m, 400 KW ] The mean design Bond's work
index of the ore was 8.1 Kw/short ton or 9.2 Kwh/MT. The ground pulp of -0.07mm, D 80 0.045 mm is thickened in 38
m dia , 3.5 m deep High rate thickener having a minimum design capacity of 222 tph at minimum 55%S in under flow.
The thickened ground ore pulp is dewatered in Filter Presses – 06 Nos. (Size : 1.5 mtr x 1.5 mtr of DKZG 350/1500-
U- 40 tph/ set.) and 03 Nos. (Size : 2 m x 2 m of DKZG 650/2000U - 80 tph/set.) at total maximum design rate of
480 tph at 10-12% moisture. The average available hours is 6000 hrs/ year for feed preparation unit also. The
conversion factor filter cake to pellet produced is 1.2 taking care for moisture, LOI and dust losses. The current grate
kiln 0.6MTPA pellet plant has been able to enhance production to 0.9MTPA for domestic and custom uses by using
the coarse feed granulometry, improving the bed depth permeability and pellet porosity and mainly enhancing the
available hours by 25%. This has led to enhancing the milling and filtering capacity to 180 tph. The bottle neck
appears in milling circuit.. Currently debottlenecking is done by reducing the feed size by feeding the - 5 mm feed
size, converting the primary spiral classifier - grate ball mill closed circuit to open circuit and increasing the size of
MOG to -0.3 mm 60%-0.045 mm,.
SM is on the threshold of increasing the capacity of pellet plant by having a 10% larger version of Grate Kiln
pellet plant of present 0.6 MTPA. Hence the expected production of pellets will be 2 MTPA if the present trend is
followed necessitating 2.4 MTPA filter cake at 400 tph/ 8000tpd / 200000 tpm. This has led to have a revalidation
study on grinding and dewatering studies. SM has already in the process of installing another 38 m dia , 3.5 m deep
HRT thickener of minimum 222 tph capacity and a matching Larox pressure filter to assure filter cakes of 600 tph
even for another expansion of pellet plant.

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2 AIM OF THE VISIT
The aim of the visit to Jamuria West Bengal and Sambalpur Orissa pellet feed preparation facilities was
mainly to observe, interact and evaluate the possibility of enhancing the milling capacity to a minimum 400tph [ 200
tph per single line] /8000 tpd/200000 tpm and 2.4MTPA. The Jamoria unit was visited form 3rd to 5th October 2018
along with Shri T V Jagadeesh, CEO, TVJMPPL of TVJ group. Similarly the Sambalupiur unit was visited from 27th
to 30 th December 2018. The flow sheet and equipment data of the present circuit was given.
3 ACTIVITY
1 Jamoria unit was visited form 3rd to 5th October 2018 along with Shri T V Jagadeesh, CEO, TVJMPPL of
TVJ group. The discussions were held with S/Sri Sanjay Singh Vice President, Mohan Bothan, GM Process and
Vishal Daga Mateials department. The milling production data, size analysis data of products in and out of milling
circuit was evaluated. Both the milling lines were operational and a mean 150 tph / lane was realized. for a finer
granulometry. The maximum tph/ lane was found to be 175 tph/ lane. Both the lanes were operational to give a -0.2
mm , 70%-0.045 mm 12% moisture cakes. We were informed that the granulometry and feed grade depends on the
pellet market .Export / premium value pellets needs high quality pellets with high strength, reducibility and grade
Fe>65%. The pellets for domestic/ internal consumption may be medium strength, medium grade of >62.5%.
2 The Sambalupiur unit was visited from 27th to 30 th December 2018. The discussions were held with
S/Shri Devkumar Tiwari, Director, Ramesh Babu GM[pellets] and Mr Naidu In-charge and Manager [Beneficiation]
The Sambalpur unit was achieving the 175 tph using a single lane only during the visit.
3 Mr Brij Bhushan Agarwal Vice Chairman and Managing Director was briefed about the visit who sought
immediate short term modifications, medium term modifications and Long term modifications keeping growth rate in
view. Mr Vishal Daga was also appraised of the visit of Sambalpur unit
4 OBSERVATIONS
1. It was observed that iron ore fines grinding and filtration facility for pellet preparation without any
separation/ up gradation is termed as beneficiation.
2. The Bonds work index of the ore type is 9.2 KWH/ metirc ton. The feed contains about 20% + 5 mm over
size and the - 5 mm contains about 33.3% -0.3 mm size. The pellet plant accepts a cake of -0.3 mm size, 50-60 %
minus 0.045 mm with 10-12% moisture. The primary and secondary milling cirucuit can take a minimum capacity
of 65 tph / mill and a peak maximum capacity of 140 tph / mill. This is confirmed by daily minimum production of 160
tph/ line.for 800 KW power
3. The series grinding circuit has a knife edge operation as far as availability and productivity is concerned as
50% of capacity gets crippled for a small stoppage.
4. Duplex Classifier with 2 screws of 1.85 m dia x 11.5 m long triple pitch, 3 starts with adjustable overflow
weirs and full flared tank of 4.8 m width and max depth of 2.78 m with a maximum capacity of 600 tph. The slope is
3"/foot or 14-15 degrees and is fed with 40- 50 %S pulp leading to settling of -0.3 mm particles .
5. The spiral classifier sands/ feed to primary mill also contain considerable amount of finished -0.3 mm
material leading to wastage of capacity of primary mill in open circuit.
6. The secondary mill is in closed circuit with hydrocyclone with 200% circulating load leading generation of
over ground particles due to reporting of significant amount of 33% finished material of -0.3mm in cyclone UF
7. It is found that open circuit primary grate ball mill is running close to its maximum capacity as compared to
secondary closed circuit over ball mill grinding as mentioned by respective relatively high amps of 22 and 16 . Each
line has reported an average of 150 tph with a maximum of 175 tph. Effective removal of finished material of -0.3 mm
at every stage can increase the capacity to 200 tph confirmed by the work index calculations of the whole circuit at
282 tph with out -0.3 mm material in feed and 352.5 tph for actual feed of - 5mm including -0.3mm fraction . The
primary mill has to be fed with 130-140 tph of -5+0.3 mm and ground to -1mm , D 80 0.77mm. The secondary mill has
to grind the +0.3mm fraction in closed circuit with cyclone- HF Screens of 0.3 mm aperture at 100% circulating load
at 140-150 tph to -0.3 mm size.
8. GM [Pellet] Sambalpur indicated to have a stacker reclaimer for blending of diverse feed, which may be
taken up at appropriate stage before expansion, .under long term modification.

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5 POINTS BY THE TEAM of TVJMPP and SM FOR ENHANCING THE CAPACITY
1. It was mutually agreed by all, that the dewatering facility has enough capacity more than 400 tph, meeting
the requirements of pellet plant. Also installation of Larox pressure filter with proven record of yielding cakes less
than 10% moisture, makes a right blend of moisture and productivity when complimented with existing filter presses.
The spiral classifier is also having enough capacity to handle 250 tph/ unit.
2. Though the normal availability hours of single closed circuit ball mill is 7200 hours/year, 6000 hours/ year
has been taken, due to series grinding circuit. The pellet plant operating hours is more than designed increasing the
productivity to 150% of design value. This has forced to increase the cake production rate at 180tph/3600 tpd/90000
tpm and 1080000 tpa. At present this is being met either by single circuit as in case of Sambalpur unit or using both
the circuits in case of Jamoria unit.
3. The team expressed maximum capacity of grinding unit on a single count would be 350 tph or 175
tph/line .With the induction of second pellet plant the expected production of pellets will be 2 MTPA necessitating 2.4
MTPA filter cake at 400 tph/8000tpd/200000 tpm..
4. The Process managers and engineers at Jamoria unit opined scientifically that fine crushing of feed to -2mm
following the theme of crush more and grind less can enhance the capacity to max 400 tph/ 8000tpd / 200000 tpm
Additional hydrocyclones and revalidation of pump may also be needed for primary mill discharge and closed circuit
secondary grinding. The process manager and engineers of Sambalpur agreed to the induction of hydrocyclones,
but differed on the use of fine hammer milling of feed to - 2mm as it may lead to loss of revenue of +5mm material
besides incorporating crushing cost of + 2 mm fraction and difficulties faced in dry screening of feed at 2 mm size.
The points appear to be logical and hence it was agreed to keep in abeyance the fine feed preparation proposal.
5. The suggestion of TVJMPP for producing the classifier over flow of -0.3mm by increasing the angle from
present 14-15 degrees or 3 inches/foot slope to 18 degrees or 4 inches / foot slope maintaining slightly thick feed
pulp density of 60%S instead of 50%S with the aim of reducing %- 3 mm in classifier sands in primary ball mill feed
was accepted and the supplier of classifier Durga Metals Belgaum .opinion may also be sought. The raking sands
have to be intensely washed also with pressure sprays.. It was bought to the notice that implementation of above
option in other iron ore milling circuit has enhanced the capacity by 10%.Conversion of grate to Or mill was dropped.
6. The suggestion of TVJMPP to employ high frequency screens in secondary grinding circuit was discussed
in detail. The stake holders were informed that screen-mill circuit has 25% capacity enhancement as compared to
hydrocyclone mill grinding circuit due to reduction of circulating load, high efficiency of screen in removal of finished
misplaced material entering the mill. As a safety factor it was decided to carryout screening of cyclone under flow
and sends the screen over size to secondary ball mill though it is not the practice. Site evaluation needs to be done.
7. The suggestion of converting primary ball mill into closed circuit with 1 mm repulp high frequency screen
was discussed. Due to the space limitation and drop in primary mill tonnage, the concept was dropped.
8. The suggestion of converting each mill to a screen – ball mill circuit which gives 430 tph for 4Nos 0.3 mm
screen-2.7 x3.6 m mill circuit though attractive, was not accepted as total milling circuit needs revamping
9. Manager of Sambalpur unit informed that high grade magnetite ore fines are available. The work index of
the ore fines is to be evaluated and if it lower than the present work index of 9.2Kw/MT, - 5mm of it may be used
provided S,P, Titania contents are low. as it helps in maintaining alumina- silica modulus of pellets and saves energy
in pelletization.
10. It was suggested to have an additional ball mill- cyclone-stack sizer circuit.
a) For a design capacity of 400 tph equivalent to the present one, the size of the mill will be 16’ x20’ with 3000
HP drive. With a 0.3 mm screen high frequency screen – ball mill circuit the through put can reach a
maximum of nearly 730 tph keeping the 33% -0.3mm in- 5 mm feed, 10% extra capacity due to high
diameter factor and 25% extra capacity due to reduction of circulating load and efficient screening
b) For a design capacity of 200 tph equivalent to single lane of the present circuit will be 0.3mm screen and
12’ x16’ over flow mill with 1500 HP drive. The above circuit can have maximum capacity of nearly 350 tph
keeping the 33% -0.3mm in- 5 mm feed, 10% extra capacity due to high diameter factor and 25% extra
capacity due to reduction of circulating load and efficient screening.
Option 10 b) seems logical and can cater for similar pellet expansion in futurewith flexibility of using existing lines.

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6 SUGGESTIONS
The suggestion are termed as short term, medium and long term modifications

The short term modifications are as follows.

1 The maintenance schedule of the milling circuit has to be organized in a organized schedule as for a single
line175 tph./ 3500 tpd / 87500 tpm is possible just meeting the present pellet plant requirement as
demonstrated in case of Sambalpur plant.
2 Removal of -0.3 mm in – 5 mm feed by increasing the tilt of classifier to 4”/ft or 18-19 degrees, maintaining
correct %S in classifier can increase the tonnage to primary ball mill.. Addition of 250 mm hydrocyclones
to get -0.3 mm in over flow of primary mill discharge and optimizing the present 100 mm hydrocyclones -
secondary mill circuit can increase the tonnage close to 200 tph max [ 190 tph average] for each line and
for feeds containing 33% -0.3mm in – 5mm feed.

The medium term modifications are as follows

1 Subsequent to implementation of above short term modifications, Implementing 0.3mm high frequency
screens for cyclone under flow for removing the misplaced finished -0.3mm material in it followed by
grinding in secondary ball mill maintaining %S may increase the tph of circuit to 225 tph maximum [ 200tph
average] for each line. Thus both the lines can reach a maximum tonnage of 400 -440 tph which just
suffices the targeted production of 2.4million tons/year filter cake for 2 million tons per year of pellet.
2 It is advisable to run each mill with screen[0.2/0.3mm screen and mill] of feed as it reduces the down time
hours and increases the capacity of each mill to 110ph when it is in close circuit and fed with ore fines
When this is to be followed, the entire primary system of wet 5mm screen, spiral classifier gets revamped. In
the beginning one lane may be attempted as the other lane in series grinding circuit operating at 175 tph
will be meeting the present production requirement. This suggestion was not conducive to some of
operating plant personnel especially from Sambalpur though the benefits are better than as of now.
The long term modification is given below
1 For a design capacity of 200 tph equivalent to single lane of the present circuit will be 0.3mm screen and
12’ x16’ over flow mill with 1500 HP drive. The above circuit can have maximum capacity of nearly 350 tph
keeping the 33% -0.3mm in- 5 mm feed, 10% extra capacity due to high diameter factor and 25% extra
capacity due to reduction of circulating load and efficient screening
2 As a revolutionary concept For a design capacity of 400 tph equivalent to the present one the size of the
mill will be 16’ x20’ with 2250KW drive. With a 0.3 mm screen high frequency screen – ball mill circuit the
through put can reach a maximum of nearly 730 tph keeping the 33% -0.3mm in- 5 mm feed, 10% extra
capacity due to high diameter factor and 25% extra capacity due to reduction of circulating load and
efficient screening
The long term modification 1 may be accepted as there will be three lanes offering flexibility.

7 CONCLUSIONS
M/s Shyam Metallic [SM], Kolkatta who is expanding the capacity of pellet plants requested TVJMPP
Bangalore to study possibility of increasing milling circuits capacity matching the enhanced capacity of pellet plant
on a promotional basis. The short term, medium and long term modifications of milling circuit gives tph of 360 tph,
420 tph and 750 tph respectively meeting just target. meeting target with cushion and not only meeting the target
but caters the future expansion also respectively This is based on present work index of ore of 9.2KWhr/MT, fine
feed of -5 mm and coarse MOG of -0.3mm, 50-60%-0.045 mm.

8 ACKNOWLEDGEMENTS
Dr B P Ravi, Advisor [ Mineral processing] and his team of TVJMPPL, Bangalore wish to express thanks to
the management and executives of Shyam Metallics Kolkata West Bengal, Jamoria West Bengal and Sambalpur
Orissa for the keen interest in validation milling capacity enhancement study on promotional basis. TVJMPPL can
assist SM in this endeavor